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Predictive maintenance with intelligent components from igus®

Smart plastics as active shapers of smart factories

With igus energy chains, cables and plain bearing products, we aim to improve the technical performance of your equipment on site, or reduce your costs. Ideally, we can improve technical performance and lower your outgoings by providing products from igus that are more wear-resistant and have to be replaced less frequently. The sensors and isense systems enable predictive maintenance of e-chains, dry-tech plain bearing products and chainflex cables.
Defects are detected before they occur, downtimes are avoided, repair times are shortened due to early intervention, and machine availability is increased. Scheduled maintenance inspections become unnecessary and employees can be more effectively employed.

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Predictive maintenance smart plastics

How does predictive maintenance work?

Under the name "isense", igus supplies various sensors that detect the status of igus components such as cables and energy chains. They measure wear, among other things, and alert the user or switch off the machine as soon as a component needs to be repaired or replaced. By networking with the icom communication module, the data is transmitted to an intelligent system. The module can be connected to all igus isense sensors. For example, with sensors for the measurement of abrasion or the amount of wear of the energy chain's pin/bore connection, as well as sensors for the detection of breakage and push/pull forces and for cable monitoring as well.
Once the measured values from a sensor have been transferred to the icom module, they have to be "interpreted" in order to generate instructions about what now needs to be done. This is possible via the connection to the igus cloud. Due to the increasing importance of IT security, however, many companies are increasingly relying on creation of their own SCADA systems. This is why igus has developed the "icom. plus" model. With this module, individual customers can integrate the data in the way that is most appropriate for their equipment and their company.


With the and icom communication models from igus, you can decide how you would like to use the data acquired via the sensors. When you want to integrate the data into your system or read out the data, you are free to do so offline in the case of restrictive environments or establish a link to the igus server. module module

The module displays the initially calculated time
of trouble-free operation on the equipment monitor.

  • Module for the isense offline system
  • Indication of service life by means of the equipment monitor
  • Alarm function in the event of problems
  • Indication in good time that maintenance is necessary
  • Compatible with the sensors: EC.W, EC.I, EC.PP

icom module

icom module

Due to digital networking, the module shows the length of time of fault-free operation in real time.

  • Module for the isense online system
  • Continuous overview of the service life in real time, in all parts of the production plant thanks to "machine learning"
  • Comparison with the igus server via IoT
  • Indication of information through web dashboard or customer display
  • Definition of limits and alarm if limits are exceeded
  • Alarm output on dashboard and also by e-mail and SMS
  • Compatible with the sensors: EC.M, EC.W, EC.I, EC.PP

isense sensors for following product areas

igus supplies sensors for energy chains, chainflex cables and bearing technology

Sensors for energy chains

Sensors for energy chains
Sensors for smart energy chains

Sensors for cables

Sensors for cables
Sensors for smart cables

Sensors for bearing technology

Sensors for bearing technology
Sensors for smart bearing technology

How do I find the right system?

Sensor selection

There are several ways of finding the right system. Starting from the area of use, for example energy chains, or with the question of what is to be achieved with the systems. Are the systems to be used for predictive maintenance where the remaining service life is displayed or is an alarm to be given in the event of components becoming worn or defective?

Selection of the method of integration into your own infrastructure and how the systems are networked within it

isense online

isense online

Comprehensive solution thanks to online mode

Online monitoring and predictive maintenance with the icom module, machine learning and networking with the igus cloud and IoT (Internet of Things).

isense offline

isense offline

Where there are high IT security requirements

Offline monitoring and predictive maintenance of energy chains, cables and bearings. With the icom. plus, the display of information is integrated into the customer's own system.  

isense stand-alone

isense stand-alone

Avoid equipment failures in the event of/after defects

In the case of an existing or imminent defect, the systems recommend a machine stop in order to prevent damage to the entire application.

isense integration

isense integration

Full integration into your system

Output of alarms, service life data and raw sensor data to the customer's existing system. Online and offline use possible.

A wide range of smart plastics products is available.
Please fill in the form so that we can put together a suitable system that is tailored to your specific needs.

Send us your enquiry for your smart project now

The most fascinating projects with igus smart plastics

Further information

"smart plastics" brochure

Download the "igus smart plastics" brochure (PDF)

igus test lab

Tested! In the industry's largest test lab